Approach and Case Study for Optimum Copper Tankhouse Design

Global refined copper demand continues to rise, mainly due to increased electrification, such as electric vehicles. Electrolysis is the primary method for refining copper today and in the foreseeable future. This places significant importance on achieving optimum designs for brownfield and greenfield tankhouse projects. While the overall concepts and designs of tankhouses have remained largely consistent for nearly a century, technological advances have driven significant incremental improvements and optimizations, setting modern plants apart from those of the past. These advancements include automation, robotics, improved process equipment efficiency, monitoring systems, and information management. This paper outlines an approach for optimal tankhouse design aimed at owners and designers seeking to understand modern design practices and tailor solutions for their specific projects. It highlights optimization opportunities for both brownfield and greenfield projects using new technologies. While “optimal” varies by project, the universal framework offers a flexible methodology for diverse scenarios. This paper references a recent European refinery rebuild project where the client needed a basic engineering package for a new 230 kt/a copper tankhouse. By closely collaborating with the client, the design team proposed operational optimizations, resulting in a best-in-class tankhouse design. The project improved upon the previous facility and included flexibility for expansion to 350 kt/a of cathode production.